Unit 4

Pug Cutting Machine

The Pug Cutting Machine is used for precision flame cutting of MS plates and structural steel components. It facilitates accurate straight-line and profile cutting as per approved drawings and fabrication requirements.

The machine is primarily used for cutting components such as bridge girder plates, gusset plates, stiffeners, connection plates, and other structural members. Proper machine settings and cutting parameters shall be maintained to ensure dimensional accuracy, uniformity, and quality of cut edges.

CNC Plasma Cutting Machine

The CNC Plasma Cutting Machine is used for high-precision cutting of MS plates and structural steel components with complex and intricate profiles. The machine operates as per approved drawings and programmed cutting parameters to achieve accurate and consistent dimensions.

It ensures uniformity, repeatability, smooth cutting profiles, and optimum material utilization, thereby minimizing material wastage. The machine is primarily used for manufacturing bridge fabrication components, connection plates, gusset plates, stiffeners, and other intricate structural components.

CNC Drilling Machine / VMC

The CNC Drilling Machine/ VMC is used for high-precision drilling, boring, tapping, and machining of holes in MS plates and structural steel components. The machine operates through CNC programming based on approved drawings and specified dimensions.

It ensures accurate hole positioning, consistent hole diameter, repeatability, and dimensional accuracy, particularly for critical structural connections. The machine is primarily used for machining flange plates, end plates, gusset plates, splice plates, base plates, and other bridge and structural fabrication components.

Radial Drilling Machine

The Radial Drilling Machine is a heavy-duty machining equipment used for accurate drilling of holes in thick plates and heavy structural components. It is suitable for drilling large-diameter holes and components requiring variable hole locations and flexible positioning.

The machine is primarily used for drilling connection plates, end plates, base plates, gusset plates, and other heavy structural members. It ensures accurate hole positioning, proper alignment, dimensional accuracy, and consistent drilling quality as per approved drawings and specified requirements.

Magnetic Core Cutting Machine

The Magnetic Drilling Machine is used for efficient and precise drilling of holes in structural steel members and fabricated components. It provides accurate hole positioning and smooth hole finishing, particularly where conventional drilling methods are difficult or impractical.

The machine is suitable for shop-floor as well as site applications, especially for drilling holes in large or assembled structural members where accessibility is limited. It ensures accuracy, ease of operation, and consistent drilling quality as per approved drawings and specified requirements.

MIG Welding Machine

MIG (Metal Inert Gas) Welding Machines are used for high-quality and efficient welding of structural steel components. The process provides consistent and controlled weld deposition, ensuring adequate penetration, strength, and uniformity of welded joints.

MIG welding is suitable for the fabrication of bridge girders, structural members, connection plates, stiffeners, and other steel components. Welding shall be carried out in accordance with the approved welding procedures, drawings, and applicable quality requirements to ensure reliable and defect-free weld joints.

SAW Welding Machine (Submerged Arc Welding)

SAW (Submerged Arc Welding) Machines are used for high-quality welding of heavy structural steel components, particularly for girders, built-up sections, and long continuous seam welds.

The process provides deep and consistent penetration, uniform weld quality, high deposition rates, and improved productivity. It is particularly suitable for long and continuous weld joints, ensuring the required strength, dimensional stability, and durability of fabricated structural components.

SAW welding shall be carried out in accordance with the approved Welding Procedure Specification (WPS), drawings, and applicable quality requirements.

Straightening Machine

The Straightening Machine is used to correct distortion, bending, and deformation in plates and structural members resulting from cutting, welding, or other fabrication processes.

The machine ensures that fabricated components achieve the required straightness, alignment, and dimensional tolerances as specified in the approved drawings and applicable standards. Straightening shall be carried out carefully to avoid damage or excessive deformation to the material before further machining, assembly, or erection activities.

End Face Milling Machine

The End Face Milling Machine is used for precision machining and finishing of the end faces of girders, beams, columns, and other structural components. It ensures accurate end dimensions, squareness, and smooth mating surfaces.

The machine facilitates proper alignment and fit-up of structural components during assembly, particularly for bridge fabrication works. Machining shall be carried out as per the approved drawings, specified tolerances, and applicable quality requirements.

Vertical Beam Welding Machine

The Vertical Beam Welding Machine is a specialized automated welding system used for the fabrication and welding of H-beams, I-sections, and other built-up structural members. The machine provides consistent weld quality, accurate alignment, uniform weld deposition, and improved productivity, ensuring reliable and structurally sound welded joints. It is primarily used for manufacturing primary load-bearing members such as bridge girders, columns, and built-up beams.

Welding shall be carried out in accordance with the approved Welding Procedure Specification (WPS), fabrication drawings, and applicable quality requirements.

6-Wheel Automatic Blasting Machine

The 6-Wheel Automatic Blasting Machine is a dedicated surface preparation system used for the abrasive blasting of steel plates, structural members, and fabricated components. The machine effectively removes rust, mill scale, oil, dirt, and other surface contaminants to achieve the specified level of surface cleanliness and surface profile. This process provides a suitable substrate for subsequent metallizing, priming, or painting operations, ensuring proper coating adhesion, durability, and long-term corrosion protection. Blasting shall be carried out in accordance with the approved surface preparation procedure, specified surface cleanliness requirements, and applicable coating specifications.

Metallizing

The Metallizing Shop is equipped for thermal spray coating of fabricated steel components, using materials such as zinc or aluminium to provide effective protection against corrosion. The metallizing process provides a durable protective coating by forming a corrosion-resistant barrier on the prepared steel surface. It enhances the service life, durability, and corrosion resistance of steel bridge components, particularly those exposed to marine, industrial, humid, or other aggressive environmental conditions. Metallizing shall be carried out in accordance with the approved metallizing procedure, specified coating thickness, surface preparation requirements and applicable quality standard.

Airless Painting Facility

The Airless Painting Facility is a controlled painting area equipped with airless spray-painting equipment for the application of primer, intermediate, and finish coats on fabricated steel components. The system provides uniform coating thickness, consistent coverage, and efficient application, ensuring the required quality and finish as specified in the approved project specifications. Painting shall be carried out in accordance with the approved painting procedure, specified coating system, surface preparation requirements, environmental conditions, and applicable quality standards.

Assembly Area

The Assembly Area is a designated facility for the trial assembly, fit-up, and dimensional verification of fabricated structural components prior to dispatch. Trial assembly is carried out to verify component alignment, bolt-hole matching, connection fit-up, overall geometry, and dimensional accuracy in accordance with approved drawings and specified tolerances. This process helps identify and rectify fabrication or fit-up discrepancies before dispatch, thereby minimizing erection difficulties and ensuring smooth assembly at site.

Stacking and Storage Area

The Stacking and Storage Area are a designated facility for the systematic storage and handling of finished, semi-finished, and fabricated steel components. Materials are stored in an organized manner to prevent damage, deformation, contamination, and mix-up, while maintaining proper identification and traceability. The area is arranged to facilitate safe handling, inspection, loading, and transportation of fabricated components to the project site.

EOT Cranes

Electric Overhead Travelling (EOT) Cranes are provided in the fabrication and assembly areas for the safe and efficient handling of heavy plates, structural members, girders, and fabricated components. The cranes facilitate the safe movement and positioning of materials between cutting, welding, assembly, inspection, and stacking areas, thereby reducing manual handling and improving operational efficiency.

All lifting and handling operations shall be carried out in accordance with the rated lifting capacity, approved lifting procedures, and applicable safety requirements, ensuring workplace safety and preventing damage to materials and equipment.

Hydra Crane

The Hydra Crane is used for heavy lifting, shifting, and material handling of fabricated steel components, particularly for transferring large and long structural members between the fabrication shed and external areas. It supports various operations including assembly, stacking, loading, unloading, and erection activities, ensuring safe and efficient handling of oversized and heavy components. All lifting operations shall be carried out within the rated capacity of the crane and in accordance with approved lifting procedures and applicable safety requirements, ensuring safe material handling and improved operational efficiency.